U.S. patent application number 16/594796 was filed with the patent office on 2020-04-23 for press device, and method of manufacturing elliptical-cylindrical member.
The applicant listed for this patent is FUTABA INDUSTRIAL CO., LTD.. Invention is credited to Daisuke Izumikawa, Hiromiki Koyama.
Application Number | 20200122210 16/594796 |
Document ID | / |
Family ID | 70280134 |
Filed Date | 2020-04-23 |
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United States Patent
Application |
20200122210 |
Kind Code |
A1 |
Izumikawa; Daisuke ; et
al. |
April 23, 2020 |
PRESS DEVICE, AND METHOD OF MANUFACTURING ELLIPTICAL-CYLINDRICAL
MEMBER
Abstract
A press device includes: a first die having a shape of an
elliptical cylinder; a second die having a first recess that forms
a part of an elliptical-cylindrical space configured to arrange the
first die therein; a third die having a second recess to be
combined with the first recess to form the elliptical-cylindrical
space; a first press mechanism that inserts the first die along a
radial direction of the first die to the first recess of the second
die over which the flat metal stock is placed so as to press the
metal stock; and a second press mechanism that moves the third die
relative to the first die inserted to the first recess so as to
confine the first die and the metal stock in the
elliptical-cylindrical space formed by the first recess and the
second recess.
Inventors: |
Izumikawa; Daisuke;
(Okazaki-shi, JP) ; Koyama; Hiromiki;
(Tsushima-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FUTABA INDUSTRIAL CO., LTD. |
Okazaki-shi |
|
JP |
|
|
Family ID: |
70280134 |
Appl. No.: |
16/594796 |
Filed: |
October 7, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 5/015 20130101;
B21D 51/10 20130101 |
International
Class: |
B21D 5/01 20060101
B21D005/01 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 19, 2018 |
JP |
2018-197733 |
Claims
1. A press device that presses a flat metal stock into an
elliptical cylinder, the press device comprising: a first die
having a shape of an elliptical cylinder; a second die having a
first recess that forms a part of an elliptical-cylindrical space
configured to arrange the first die therein; a third die having a
second recess to be combined with the first recess to form the
elliptical-cylindrical space; a first press mechanism that inserts
the first die along a radial direction of the first die to the
first recess of the second die over which the flat metal stock is
placed so as to press the metal stock; and a second press mechanism
that moves the third die relative to the first die inserted to the
first recess so as to confine the first die and the metal stock in
the elliptical-cylindrical space formed by the first recess and the
second recess, thereby pressing an unpressed portion of the metal
stock that is not inserted to the first recess.
2. The press device according to claim 1, wherein the second press
mechanism has ends of the metal stock butted against each other at
an apex intersecting a major axis of an ellipse, when viewed from a
central axis direction of the first die.
3. The press device according to claim 1, wherein a portion on an
outer circumferential surface of the first die facing the first
recess has a smaller curvature radius than a portion of the first
recess facing that portion of the first die.
4. The press device according to claim 1, further comprising: a
guide mechanism to guide the unpressed portion of the metal stock
toward the first die in a state in which the first die is inserted
to the first recess.
5. A method of manufacturing an elliptical-cylindrical member using
a flat metal stock, the method comprising: preparing a first die
having a shape of elliptical cylinder, a second die having a first
recess that forms a part of an elliptical-cylindrical space
configured to arrange the first die therein, a third die having a
second recess to be combined with the first recess to form the
elliptical-cylindrical space; placing the flat metal stock over the
first recess; inserting the first die along a radial direction of
the first die to the first recess of the second die over which the
metal stock is placed so as to press the metal stock; and moving
the third die relative to the first die inserted to the first
recess so as to confine the first die and the metal stock in the
elliptical-cylindrical space formed by the first recess and the
second recess, thereby pressing an unpressed portion of the metal
stock that is not inserted to the first recess.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Japanese Patent
Application No. 2018-197733 filed on Oct. 19, 2018 with the Japan
Patent Office, the entire disclosure of which is incorporated
herein by reference.
BACKGROUND.
[0002] The present disclosure relates to a press device, and a
method of manufacturing an elliptical-cylindrical member.
[0003] A known method for manufacturing a metal member in the form
of an elliptical cylinder is pressing a true cylindrical body
having a core metal inside with an upper die and a lower die (see
Japanese Unexamined Patent Application Publication No.
2011-161446).
SUMMARY
[0004] In the above method, since the core metal does not contact
the inside of an apex portion (that is, portion having a minimum
curvature radius) of the cylindrical body that intersects a major
axis of an ellipse, press-forming of this portion becomes
insufficient. Therefore, shape accuracy of the obtained member
decreases.
[0005] In one aspect of the present disclosure, it is preferable to
provide a press device that can form an elliptical-cylindrical
member with high shape accuracy.
[0006] One aspect of the present disclosure provides a press device
that presses a flat metal stock into an elliptical cylinder. The
press device comprises a first die, a second die, a third die, a
first press mechanism and a second press mechanism. The first die
has a shape of an elliptical cylinder. The second die has a first
recess that forms a part of an elliptical-cylindrical space
configured to arrange the first die therein. The third die has a
second recess to be combined with the first recess to form the
elliptical-cylindrical space. The first press mechanism inserts the
first die along a radial direction of the first die to the first
recess of the second die over which the flat metal stock is placed
so as to press the metal stock. The second press mechanism moves
the third die relative to the first die inserted to the first
recess so as to confine the first die and the metal stock in the
elliptical-cylindrical space formed by the first recess and the
second recess, thereby pressing an unpressed portion of the metal
stock that is not inserted to the first recess.
[0007] According to the configuration as such, the metal stock can
be pressed into an elliptical cylinder with the second die and the
third die while the first die is brought into contact with the
metal stock from inside of an apex portion that intersects a major
axis of the elliptical cylinder. Therefore, decrease in shape
accuracy of the apex portion of the elliptical-cylindrical member
can be reduced. As a result, shape accuracy of the
elliptical-cylindrical member can be improved.
[0008] In one aspect of the present disclosure, the second press
mechanism may have ends of the metal stock butted against each
other at an apex intersecting a major axis of an ellipse, when
viewed from a central axis direction of the first die. According to
the configuration as such, decrease in shape accuracy of the apex
portion intersecting the major axis can be reliably reduced.
[0009] In one aspect of the present disclosure, a portion on an
outer circumferential surface of the first die facing the first
recess may have a smaller curvature radius than a portion of the
first recess facing that portion of the first die. According to the
configuration as such, a force can be exerted in a direction in
which the metal stock is closed at a portion arranged in the first
recess together with the first die by the first press mechanism
while shape accuracy of the apex portion of the
elliptical-cylindrical member is maintained. Therefore, it is
possible to suppress springback of a portion of the metal stock
arranged in the second recess together with the first die by the
first press mechanism. As a result, shape accuracy of the
elliptical-cylindrical member can be further improved.
[0010] In one aspect of the present disclosure, the press device
may further comprise a guide mechanism to guide the unpressed
portion of the metal stock toward the first die in a state in which
the first die is inserted to the first recess. According to the
configuration as such, when the second press mechanism operates,
the unpressed portion of the metal stock can be easily and reliably
guided into the second recess. As a result, productivity of the
elliptical-cylindrical member can be increased.
[0011] Another aspect of the present disclosure provides a method
of manufacturing an elliptical-cylindrical member using a flat
metal stock. The method comprises: preparing a first die having a
shape of elliptical cylinder, a second die having a first recess
that forms a part of an elliptical-cylindrical space configured to
arrange the first die therein, a third die having a second recess
to be combined with the first recess to form the
elliptical-cylindrical space; placing the flat metal stock over the
first recess; inserting the first die along a radial direction of
the first die to the first recess of the second die over which the
metal stock is placed so as to press the metal stock; and moving
the third die relative to the first die inserted to the first
recess so as to confine the first die and the metal stock in the
elliptical-cylindrical space formed by the first recess and the
second recess, thereby pressing an unpressed portion of the metal
stock that is not inserted to the first recess.
[0012] According to the configuration as such, the metal stock can
be pressed into an elliptical cylinder by the second die and the
third die while the first die is brought into contact with the
metal stock from inside at an apex portion intersecting a major
axis of the elliptical cylinder. Therefore, decrease in shape
accuracy of the elliptical-cylindrical member at the apex portion
can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] An example embodiment of the present disclosure will be
described hereinafter with reference to the accompanying drawings,
in which:
[0014] FIG. 1 is a schematic front view of a press device of an
embodiment;
[0015] FIG. 2 is a schematic perspective view of an
elliptical-cylindrical member obtained from a metal stock pressed
by the press device of FIG. 1;
[0016] FIG. 3 is a schematic front view of a first die, a first
recess and a second recess of the press device of FIG. 1;
[0017] FIG. 4 is a flow diagram of a method of manufacturing an
elliptical-cylindrical member in the embodiment; and
[0018] FIG. 5A is a schematic diagram explaining a step of pressing
the metal stock by the press device of FIG. 1, FIG. 5B is a
schematic diagram explaining the next step of the step in FIG. 5A,
and FIG. 5C is a schematic diagram explaining the next step of the
step in FIG. 5B.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
1. First Embodiment
[0019] [1-1. Configuration]
[0020] A press device 1 shown in FIG. 1 presses a flat metal stock
(that is, workpiece) into an elliptical cylinder.
[0021] An elliptical-cylindrical member P shown in FIG. 2 is
obtained by welding the metal stock pressed into an elliptical
cylinder using the press device 1. The elliptical-cylindrical
member P is used in exhaust parts such as a muffler of an
automobile and the like.
[0022] The press device 1 comprises a first die 2, a second die 3,
a third die 4, a first press mechanism 5, a second press mechanism
6, a guide mechanism 7, and a pedestal 8.
[0023] <First Die>
[0024] The first die 2 is made of metal and has a shape of an
elliptical column. The first die 2 is configured to be arranged in
an elliptical-cylindrical space formed by the second die 3 and the
third die 4 to be described later.
[0025] The first die 2 is supported by the first press mechanism 5
to be described later. In the present embodiment, the first die 2
is supported in a direction in which a central axis direction (that
is, longitudinal direction) of the elliptical column is parallel to
a horizontal direction and in which a major axis of an ellipse is
parallel to a vertical direction.
[0026] <Second Die>
[0027] The second die 3 is made of metal and has a first recess 3A
that forms a part of the elliptical-cylindrical space configured to
arrange the first die 2 therein, and a mount surface 3B configured
to mount the metal stock.
[0028] The second die 3 is supported by the pedestal 8. In the
present embodiment, the second die 3 is arranged below the first
die 2. The first recess 3A extends in the form of a groove along a
longitudinal direction of the first die 2 (that is, direction
perpendicular to a sheet surface of FIG. 1 drawing). Also, the
first recess 3A is formed in a direction in which the deepest point
is the lowest point, that is, a direction in which a major axis of
the elliptical-cylindrical space is parallel to the vertical
direction.
[0029] The mount surface 3B is a plane where the metal stock to be
pressed is placed. In the present embodiment, the mount surface 3B
is parallel to the horizontal direction (that is, horizontal
plane). Also, the mount surface 3B is brought into contact with the
third die 4 upon pressing.
[0030] In the present embodiment, the second die 3 is stationary
and is fixed in place. Therefore, when the first die 2 and the
third die 4 are moved relative to the second die 3, the metal stock
is pressed into an elliptical cylinder.
[0031] <Third Die>
[0032] The third die 4 is made of metal and has a second recess 4A
to be combined with the first recess 3A to form the
elliptical-cylindrical space, and a bottom surface 4B which is
brought into contact with the second die 3.
[0033] The third die 4 is supported by the second press mechanism 6
to be described later. In the present embodiment, the third die 4
is arranged above the first die 2. The second recess 4A extends in
the form of a groove along the longitudinal direction of the first
die 2. Also, the second recess 4A is formed in a direction in which
the deepest point is the highest point, that is, a direction in
which the major axis of the elliptical-cylindrical space is
parallel to the vertical direction.
[0034] As shown in FIG. 3, the first recess 3A and the second
recess 4A each have a shape obtained by dividing the
elliptical-cylindrical space into two in a plane parallel to a
minor axis of the ellipse in the vicinity of the minor axis. Also,
abutting surfaces of the second die 3 and the third die 4 (that is,
the mount surface 3B and the bottom surface 4B) are parallel to a
minor axis of the elliptical-cylindrical space.
[0035] <First Press Mechanism>
[0036] The first press mechanism 5 inserts a first portion 2A of
the first die 2 along a radial direction of the first die 2 to the
first recess 3A of the second die 3 over which the flat metal stock
is placed on the mount surface 3B so as to press the metal
stock.
[0037] In the present embodiment, the first press mechanism 5
inserts the first die 2 to the first recess 3A along a direction
parallel to the major axis of the elliptical-cylindrical space
(specifically, downward). This movement of the first die 2 curves
the metal stock along an outer circumferential surface of the first
die 2 and an inner surface of the first recess 3A, and forms a
lower half of the elliptical cylinder.
[0038] <Second Press Mechanism>
[0039] The second press mechanism 6 moves the third die 4 relative
to the first die 2 that is inserted to the first recess 3A by the
first press mechanism 5 to confine the first die 2 and the metal
stock in the elliptical-cylindrical space formed by the first
recess 3A and the second recess 4A.
[0040] In other words, the second press mechanism 6 inserts a
second portion 2B of the first die 2 that is not inserted to the
first recess 3A to the second recess 4A of the third die 4 together
with the metal stock along the radial direction of the first die 2.
As a result, the second press mechanism 6 presses the unpressed
portion of the metal stock that is not inserted to the first recess
3A.
[0041] In the present embodiment, the second press mechanism 6
moves the third die 4 along the direction parallel to the major
axis of the elliptical-cylindrical space (specifically, downward)
so as to superpose the third die 4 on the first die 2 and the
second die 3. As a result, the first recess 3A and the second
recess 4A are combined to form the elliptical-cylindrical
space.
[0042] The unpressed portion of the metal stock which is not
pressed by the first press mechanism 5 is curved along the outer
circumferential surface of the first die 2 and the inner surface of
the second recess 4A in the elliptical-cylindrical space. As a
result, the whole metal stock is processed into an elliptical
cylinder.
[0043] Also in the present embodiment, the second press mechanism 6
has the ends of the metal stock butted against each other at an
apex S (see FIG. 2) that intersects the major axis of the ellipse
by relative movement of the third die 4, when viewed from a central
axis direction of the first die 2 (that is, direction perpendicular
to a sheet surface of FIG. 1 drawing). The elliptical-cylindrical
member P is obtained by welding the abutting ends.
[0044] A curvature radius R1 of a portion (apex portion, for
example) on the outer circumferential surface of the first die 2
facing the first recess 3A is smaller than a curvature radius R2 of
a portion of the first recess 3A facing that portion of the first
die 2. Also, a clearance C is provided between the outer
circumferential surface of the first die 2 and the inner surface of
the first recess 3A.
[0045] In other words, in the first die 2, the curvature radius R1
of the outer circumferential surface of the first portion 2A
inserted to the first recess 3A is smaller than the curvature
radius R2 of the outer circumferential surface of the second
portion 2B inserted to the second recess 4A. That is, in comparison
of width in the same distance from the minor axis (that is, length
in a direction parallel to the minor axis), a width W1 of the first
portion 2A is smaller than a width W2 of the second portion 2B.
[0046] A sectional shape vertical to a central axis of the first
die 2 is a line symmetrical shape having the major axis of the
ellipse as an axis of symmetry. Also, the sectional shape of the
first die 2 is constant along the central axis direction and does
not change.
[0047] <Guide Mechanism>
[0048] The guide mechanism 7 guides the unpressed portion of the
metal stock toward the first die 2 when the first die 2 is inserted
to the first recess 3A.
[0049] Specifically, the guide mechanism 7 has a portion slidable
in a direction parallel to a minor axis of the first die 2 (that
is, horizontal direction). Also, the guide mechanism 7 is attached
to the second press mechanism 6 and moves in an up-down direction
with the third die 4.
[0050] The guide mechanism 7, for example, slides toward the first
die 2 so as to push the metal stock against the first die 2, and
guides the metal stock to the second recess 4A when the second
press mechanism 6 operates. The guide mechanism 7 separates from
the first die 2 after leading ends of the metal stock enter the
second recess 4A.
[0051] [1-2. Effect]
[0052] According to the above-detailed embodiment, the following
effect can be obtained.
[0053] (1a) The metal stock can be pressed into an elliptical
cylinder by the second die 3 and the third die 4 while the first
die 2 is brought into contact with the metal stock in the apex
portion that intersects the major axis of the elliptical cylinder.
Therefore, decrease in shape accuracy in the apex portion of the
elliptical-cylindrical member can be reduced. As a result, shape
accuracy of the elliptical-cylindrical member can be improved.
[0054] (1b) Decrease in shape accuracy in the apex portion can be
reliably reduced by having the ends of the metal stock butted
against each other in the apex S that intersects the major axis of
the ellipse by the second press mechanism 6.
[0055] (1c) The curvature radius R1 of the portion on the outer
circumferential surface of the first die 2 facing the first recess
3A is smaller than the curvature radius R2 of the portion of the
first recess 3A facing that portion of the first die 2. Therefore,
while shape accuracy of the apex portion of the
elliptical-cylindrical member is maintained, a force can be exerted
in the direction in which the metal stock is closed at the portion
arranged in the first recess 3A together with the first die 2 by
the first press mechanism 5. Thus, it is possible to suppress
springback of the portion of the metal stock arranged in the second
recess 4A together with the first die 2 by the first press
mechanism 5. As a result, shape accuracy of the
elliptical-cylindrical member can be further improved.
[0056] (1d) The curvature radius R1 of the portion of the first die
2 facing the first recess 3A is smaller than the curvature radius
R2 of the first recess 3A, and the ends of the metal stock are
butted against each other at the apex S by the second press
mechanism 6. In this way, as compared to butting at an apex that
intersects the minor axis of the ellipse, pressing by the second
press mechanism 6 can be started from a portion having a larger
curvature radius of the unpressed portion of the metal stock.
Therefore, springback after the unpressed portion is pressed can be
suppressed, and decrease in shape accuracy of the apex portion can
be reliably reduced. As a result, shape accuracy of the
elliptical-cylindrical member can be improved.
[0057] (1e) The unpressed portion of the metal stock can be easily
and reliably guided to the second recess 4A by the guide mechanism
7 when the second press mechanism 6 operates. As a result,
productivity of the elliptical-cylindrical member can be
improved.
2. Second Embodiment
[0058] [2-1. Configuration]
[0059] A method of manufacturing an elliptical-cylindrical member
shown in FIG. 4 uses a flat metal stock to obtain the
elliptical-cylindrical member P shown in FIG. 2.
[0060] The method of manufacturing an elliptical-cylindrical member
comprises a die preparation process S10, a metal stock mounting
process S20, a first press process S30, a second press process S40,
a die-removal process S50, and a welding process S60.
[0061] <Die Preparation Process>
[0062] In this process, the first die 2, the second die 3, and the
third die 4 are prepared. That is, the press device 1 shown in FIG.
1 becomes operable so that pressing can be performed.
[0063] <Metal Stock Mounting Process>
[0064] In this process, the metal stock is mounted on the mount
surface 3B of the second die 3 so that the flat metal stock is
placed over the first recess 3A.
[0065] <First Press Process>
[0066] In this process, as shown in FIG. 5A, the first die 2 is
inserted along the radial direction of the first die 2 to the first
recess 3A of the second die 3 over which the metal stock R is
placed so as to partially press the metal stock R. This process
curves the metal stock R so that the two ends of the metal stock R
face upward.
[0067] <Second Press Process>
[0068] In this process, as shown in FIG. 5B, the third die 4 is
moved relative to the first die 2 inserted to the first recess 3A
so that the first die 2 and the metal stock R are confined in the
elliptical-cylindrical space formed by the first recess 3A and the
second recess 4A. As a result, the unpressed portion of the metal
stock R that is not inserted to the first recess 3A is pressed.
[0069] At this time, the unpressed portion of the metal stock R is
guided toward the first die 2 by the guide mechanism 7. Thereafter,
the third die 4 is moved to a position to be brought into contact
with the second die 3. As a result, the elliptical-cylindrical
space is formed, and the metal stock R is curved so as to cover an
outer circumferential surface of the first die 2 in the
elliptical-cylindrical space. Pressing of the metal stock R is
complete.
[0070] <Die-Removal Process>
[0071] In this process, as shown in FIG. 5C, each die is removed
from the pressed metal stock R, and the metal stock R processed
into an elliptical cylinder is removed from the press device 1.
[0072] Specifically, the second die 3, the third die 4, and the
first die 2 are removed in this order. In the present embodiment,
firstly, the third die 4 and the first die 2 are moved upward at
the same time so as to remove the second die 3. Thereafter, only
the third die 4 is moved upward to remove the third die 4. Lastly,
the elliptical-cylindrical metal stock R is slid in the central
axis direction of the first die 2 to remove the first die 2.
[0073] When the second die 3 and/or the third die 4 is removed, the
metal stock R may be pushed on the first die 2 by the guide
mechanism 7. In this way, springback and dropping from the first
die 2 of the metal stock R can be inhibited.
[0074] <Welding Process>
[0075] In this process, the abutting ends of the metal stock R are
welded along a central axis direction of the elliptical cylinder so
as to process the metal stock R into a ring. As a result, the
elliptical-cylindrical member P is obtained.
[0076] [2-2. Effect]
[0077] According to the above-detailed embodiment, the following
effect can be obtained.
[0078] (2a) While the first die 2 is brought into contact with the
metal stock from inside at the apex portion intersecting the major
axis of the elliptical cylinder, the metal stock is pressed into an
elliptical cylinder by the second die 3 and the third die 4.
Therefore, decrease in shape accuracy of the apex portion of the
elliptical-cylindrical member can be reduced.
3. Other Embodiments
[0079] The embodiments of the present disclosure have been
described above. However, the present disclosure is not limited to
the above-described embodiments and can be modified variously.
[0080] (3a) In the press device 1 of the above-described
embodiments, it is not always necessary to have the ends of the
metal stock butted against each other at the apex intersecting the
major axis of the ellipse. In other words, the ends may be butted
against each other at an apex intersecting the minor axis, or may
be butted at a portion other than the apex.
[0081] (3b) In the press device 1 of the above-described
embodiments, the curvature radius R1 of the portion facing the
first recess 3A may not be necessarily smaller than the curvature
radius R2 of the portion of the first recess 3A facing that
portion.
[0082] (3c) The press device 1 of the above-described embodiments
may not necessarily comprise the guide mechanism 7. Also, in the
method of manufacturing the elliptical-cylindrical member in the
above-described embodiment, the unpressed portion of the metal
stock R may not be necessarily pushed on the first die 2 in the
second press process.
[0083] For example, an end on an opening side of the second recess
4A of the third die 4 may be partially widened (that is, guide
notch may be provided) to guide the metal stock R to the second
recess 4A. In this case, a convex portion that fills the notch may
be provided in the second die 3.
[0084] (3d) In the press device 1 of the above-described
embodiments, the first recess 3A and the second recess 4A may each
have a shape obtained by dividing the elliptical-cylindrical space
into two by a plane parallel to the major axis. In other words, the
first die 2 may be inserted along a direction parallel to the minor
axis of the first die 2 to the first recess 3A.
[0085] Also, the first press mechanism 5 may have the first die 2
fixed and move the second die 3, or may move both the first die 2
and the second die 3. Similarly, the second press mechanism 6 may
have the third die 4 fixed and move the first die 2 and the second
die 3, or may move all the dies.
[0086] Further, a moving direction (that is, press direction) of
the first die 2, the second die 3, and the third die 4 is not
limited to the up-down direction. In other words, the moving
direction of these dies may be a horizontal direction, or a
direction other than the up-down direction and the horizontal
direction.
[0087] (3e) A function achieved by one element in the
above-described embodiments may be divided into two or more
elements. A function achieved by two or more elements may be
integrated into one element. Further, a part of the configuration
of any of the above-described embodiments may be omitted. At least
a part of the configuration of any of the above-described
embodiments may be added to or replaced with the configuration of
the other embodiments described above. It should be noted that any
and all modes that are encompassed in the technical ideas defined
by the languages in the scope of the claims are embodiments of the
present disclosure.
* * * * *